OWNER’S

MANUAL

M 9.9
15
18
OB No.003-11049-A
! READ THIS MANUAL BEFORE USING THE OUTBOARD MOTOR. FAILURE TO FOLLOW THE
INSTRUCTIONS AND SAFETY PRECAUTIONS IN THIS MANUAL CAN RESULT IN SERIOUS
INJURY OR DEATH. KEEP THIS MANUAL IN A SAFE LOCATION FOR FUTURE REFERENCE.

Copyright © 2011 Tohatsu Corporation. All rights reserved. No part of this manual may
be reproduced or transmitted in any from or by any means without the express written
permission of Tohatsu Corporation.
YOUR TOHATSU OUTBOARD MOTOR
OWNER REGISTRATION AND IDENTIFICATION
Upon purchasing this product, be sure that the WARRANTY CARD is correctly and
completely filled out and mailed to the addressee noted there on. This WARRANTY
CARD identifies you as the legal owner of the product and serves as your warranty
registration.
TO THE EXTENT PERMITTED BY APPLICABLE LAW, YOUR OUTBOARD MOTOR
WILL NOT BE COVERED BY THE APPLICABLE LIMITED WARRANTY, IF THIS
PROCEDURE IS NOT FOLLOWED.

PRE-DELIVERY CHECK
Be sure that the product has been checked by an authorized TOHATSU dealer before
you take delivery.

Limited Warranty
Please refer to the TOHATSU outboard motor Limited warranty provided to you with
this product, the terms and conditions of which, as amended from time to time, are
incorporated by reference into the manual.
Serial Number
In the space below, please record the outboard motor's serial number (indicated both
on the bottom cowl and on the cylinder block). The serial number will be needed in the
event of theft or to quickly identifying the outboard motor type.

Serial Number :

To You, Our Customer

Thank you for selecting a TOHATSU outboard motor. You are now the proud owner of
an excellent outboard motor that will service you for many years to come.
This manual should be read in its entirety and the inspection and maintenance
procedures described later in this manual should be followed carefully. Should a
problem arise with the outboard motor, please follow the troubleshooting procedures
listed at the end of this manual. If the problem persists, contact an authorized
TOHATSU service shop or dealer.

We hope you will enjoy your outboard motor and wish you good luck in your boating
adventures.
TOHATSU CORPORATION
 CONTENTS
GENERAL SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2 NAMES OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1. Mounting the outboard motor on boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2. Installing the remote control devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3. Installing the battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 PRE-OPERATING PREPARATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1. Recommended gasoline types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2. Recommended engine oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3. Break-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1. Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2. Warming up the engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3. Forward and reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4. Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5. Trim angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6. Tilt up, tilt down and shallow water operation . . . . . . . . . . . . . . . . . . . . . . . . . 37
6 REMOVING AND CARRYING THE OUTBOARD MOTOR . . . . . . . . . . . . . . . . 40
1. Removing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2. Carrying the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
3. Storing the outboard motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7 TRAILERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
1. Steering friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2. Remote control lever load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3. Trim tab adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9 INSPECTION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
1. Daily inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2. Periodic inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3. Off-season storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4. Pre-season check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5. Motor submerged in water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6. Cold weather precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
7. Checking after striking underwater object . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
11 TOOL KIT AND SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
12 OPTIONAL ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
13 PROPELLER TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
 7

INDEX

GENERAL SAFETY INFORMATION

1. SPECIFICATIONS 1

2. NAMES OF PARTS 2

3. INSTALLATION 3

4.PRE-OPERATING PREPARATIONS 4

5.ENGINE OPERATION 5

6.REMOVING AND CARRYING THE OUTBOARD MOTOR 6

7.TRAILERING 7

8.ADJUSTMENT 8

9.INSPECTION AND MAINTENANCE 9

10.TROUBLESHOOTING 10

11.TOOL KIT AND SPARE PARTS 11

12.OPTIONAL ACCESSORIES 12

13.PROPELLER TABLE 13
8

GENERAL SAFETY INFORMATION

NOTICE : DANGER/WARNING/CAUTION/Note
Before installing, operating or otherwise handling your outboard motor, be sure
to thoroughly read and understand this Owner's Manual and carefully follow all of
the instructions. Of particular importance is information preceded by the words
"DANGER," "WARNING," "CAUTION," and "Note." Always pay special attention to
such information to ensure safe operation of the outboard motor at all times.

! ������
Failure to observe will result in severe personal injury or death, and possibly property damage.

! �������
Failure to observe could result in severe personal injury or death, or property damage.

! �������
Failure to observe could result in personal injury or property damage.

Note
This instruction provides special information to facilitate the use or maintenance of the
outboard motor or to clarify important points.

EMERGENCY STOP SWITCH

The Emergency Stop Switch will stall the outboard motor when the stop switch tether
is pulled off. This stop switch tether can be attached to the operator of the outboard
motor to minimize or prevent injuries from the propeller in case the operator falls
overboard.
We highly recommend use of the Emergency Stop Switch tether.

! �������
Accidental activation of the Emergency Stop Switch (such as the tether being pulled out
in heavy seas) could cause passengers to lose their balance and even fall overboard,
or it could result in loss of power in heavy seas, strong currents, or high winds. Loss of
control while mooring is another potential hazard.
To minimize accidental activation of the Emergency Stop Switch, the 500 mm (20 inch.)
stop switch tether is coiled and can extended to a full 1,300 mm (51 inch.).
 9

SAFE OPERATION OF BOAT

As the operator/driver of the boat, you are responsible for the safety of those aboard
and those in other boat around yours, and for following local boating regulations. You
should be thoroughly knowledgeable on how to correctly operate the boat, outboard
motor, and accessories. To learn about the correct operation and maintenance of the
outboard motor, please read through this manual carefully.
It is very difficult for a person standing or floating in the water to take evasive action
should he or she see a power boat heading in his /her direction, even at a slow speed.
Therefore, when your boat is in the immediate vicinity of people in the water, the
outboard motor should be shifted to neutral and shut off.

! �������
SERIOUS INJURY IS LIKELY IF A PERSON IN THE WATER MAKES CONTACT WITH
A MOVING BOAT, GEAR HOUSING, PROPELLER, OR ANY SOLID DEVICE RIGIDLY
ATTACHED TO A BOAT OR GEAR HOUSING.

SERVICING, REPLACEMENT PARTS & LUBRICANTS

We recommend that only an authorized service shop perform service or maintenance
on this outboard motor. Be sure to use genuine parts, genuine lubricants, or
recommended lubricants.

MAINTENANCE
As the owner of this outboard motor, you should be acquainted with correct
maintenance procedures. It is the operator's responsibility to perform all safety checks
and to ensure that all lubrication and maintenance instructions are complied with
for safe operation. Please comply with all instructions concerning lubrication and
maintenance. You should take the engine to an authorized dealer or service shop for
periodic inspection at the prescribed intervals.
Correct periodic maintenance and proper care of this outboard motor will reduce the
chance of problems and limit overall operating expenses.

MOUNTING
Outboard motor mounting must be performed by trained service person(s) using lift or
hoist with sufficient capacity.
 10

SPECIFICATIONS
9.9D2, 9.9D2 EF, 9.9D2 EP

MODEL
9.9D2 9.9D2 EF 9.9D2 EP
1 Item
Overall Length mm (in) 869 (34.2) 565 (22.2)

Overall Width mm (in) 345 (13.6) 290 (11.4)

Overall Height S·L·UL mm (in) 1,067 (42.0) · 1,194 (47.0) · 1,321 (52.0)

Transom Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1)

S kg (lb) 41 (90) 44 (97)

Weight L kg (lb) 42 (93) 45 (99)

UL kg (lb) 43 (95) 46 (101)

Output kW (Hp) 7.3 (9.9)

Max. Operating Range rpm 4,500-5,300

Number of Cylinder 2

Piston Displacement mL (Cu in) 247 (15.07)

Bore x Stroke mm (in) 55 x 52 (2.17 x 2.05)

Exhaust System Through hub exhaust

Lubrication System Engine Oil Mixed Gasoline

Cooling System Forced water cooling

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. Ignition

Spark Plug NGK B7HS-10/BR7HS-10

Trim Position 6

Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Genuine Gear Oil or API GL5,
Gear Oil
SAE #80 to #90, approx. 370mL
Fuel Tank Capacity L (US gal) 25 (6.6)

Gear Reduction Ratio 1.85 (13 : 24)

* with manual
 SPECIFICATIONS 11

15D2, 15D2 EF, 15D2 EP

MODEL
15D2 15D2 EF 15D2 EP
Item 1
Overall Length mm (in) 869 (34.2) 565 (22.2)

Overall Width mm (in) 345 (13.6) 290 (11.4)

Overall Height S·L·UL mm (in) 1,067 (42.0) · 1,194 (47.0) · 1,321 (52.0)

Transom Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1)

S kg (lb) 41 (90) 44 (97)

Weight L kg (lb) 42 (93) 45 (99)

UL kg (lb) 43 (95) 46 (101)

Output kW (Hp) 11.0 (15)

Max. Operating Range rpm 5,200-5,800

Number of Cylinder 2

Piston Displacement mL (Cu in) 247 (15.07)

Bore x Stroke mm (in) 55 x 52 (2.17 x 2.05)

Exhaust System Through hub exhaust

Lubrication System Engine Oil Mixed Gasoline

Cooling System Forced water cooling

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. Ignition

Spark Plug NGK B7HS-10/BR7HS-10

Trim Position 6

Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Genuine Gear Oil or API GL5,
Gear Oil
SAE #80 to #90, approx. 370mL
Fuel Tank Capacity L (US gal) 25 (6.6)

Gear Reduction Ratio 1.85 (13 : 24)

* with manual
 12 SPECIFICATIONS

18E2, 18E2 EF, 18E2 EP

MODEL
18E2 18E2 EF 18E2 EP
1 Item
Overall Length mm (in) 869 (34.2) 565 (2.22)

Overall Width mm (in) 345 (13.6) 290 (11.4)

Overall Height S·L·UL mm (in) 1,067 (42.0) · 1,194 (47.0) · 1,321 (52.0)

Transom Height S·L·UL mm (in) 435 (17.1) · 562 (22.1) · 689 (27.1)

S kg (lb) 41 (90) 44 (97)

Weight L kg (lb) 42 (93) 45 (99)

UL kg (lb) 43 (95) 46 (101)

Output kW (Hp) 13.2 (18)

Max. Operating Range rpm 5,200-5,800

Number of Cylinder 2

Piston Displacement mL (Cu in) 294 (17.94)

Bore x Stroke mm (in) 60 x 52 (2.36 x 2.05)

Exhaust System Through hub exhaust

Lubrication System Engine Oil Mixed Gasoline

Cooling System Forced water cooling

Starting System Manual Electric starter motor*

Ignition System Flywheel Magneto C.D. Ignition

Spark Plug NGK B7HS-10/BR7HS-10

Trim Position 6

Engine Oil Mixing Ratio Unleaded Gasoline 50 : Genuine 2-stroke Engine Oil 1
Genuine Gear Oil or API GL5,
Gear Oil
SAE #80 to #90, approx. 370mL
Fuel Tank Capacity L (US gal) 25 (6.6)

Gear Reduction Ratio 1.85 (13 : 24)

* with manual
 13

NAMES OF PARTS
9.9D2, 15D2, 18E2

1 q o p
2 w a
e
3 2
4 r

5 t

u
6

7 i

8
9

g j

s k
d
l

h ;
f

1 Tilt Handle q Starter Handle a Fuel Connector (Male)

2 Top Cowl w Shift Lever s Oil Plug (Upper)
3 Bottom Cowl e Throttle Grip d Water Plug
4 Reverse Lock Lever r Adjust Nut f Oil Plug (Lower)
5 Cooling Water Check Port t Clamp Screw g Primer Bulb
6 Drive Shaft Housing y Clamp Bracket h Fuel Tank
7 Anti Ventilation Plate u Thrust Rod j Fuel Connector (Female)
8 Anode / Trim Tab i Water Inlet k Fuel Tank Cap
9 Sub Water Inlet o Stop Switch l Air Vent Screw
0 Propeller p Choke Knob ; Fuel Pick Up Elbow
 14 NAMES OF PARTS

9.9D2 EF, 15D2 EF, 18E2 EF

1 q o s
2 w p d
e
3
2 4 r
a

5 t

u
6

7 i
8
9

j l

f ;

g z

k x
h

1 Tilt Handle w Shift Lever d Fuel Connector (Male)

2 Top Cowl e Throttle Grip f Oil Plug (Upper)
3 Bottom Cowl r Adjust Nut g Water Plug
4 Reverse Lock Lever t Clamp Screw h Oil Plug (Lower)
5 Cooling Water Check Port y Clamp Bracket j Primer Bulb
6 Drive Shaft Housing u Thrust Rod k Fuel Tank
7 Anti Ventilation Plate i Water Inlet l Fuel Connector (Female)
8 Anode / Trim Tab o Starter Switch Button ; Fuel Tank Cap
9 Sub Water Inlet p Stop Switch z Air Vent Screw
0 Propeller a Battery Cord x Fuel Pick Up Elbow
q Starter Handle s Choke Knob
 NAMES OF PARTS 15

9.9D2 EP, 15D2 EP, 18E2 EP

1 o
q
2 u p
w

3
i
2
4 e

5
r

t
6

a
7 s
y
8 d
9 f

k ;
g
z
h

j l c

1 Tilt Handle w Shift Lever d Stop Switch

2 Top Cowl e Clamp Screw f Cord Assembly
3 Bottom Cowl r Clamp Bracket g Oil Plug (Upper)
4 Reverse Lock Lever t Thrust Rod h Water Plug
5 Cooling Water Check Port y Water Inlet j Oil Plug (Lower)
6 Drive Shaft Housing u Stop Switch k Primer Bulb
7 Anti Ventilation Plate i Battery Cord l Fuel Tank
8 Anode / Trim Tab o Choke Knob ; Fuel Connector (Female)
9 Sub Water Inlet p Fuel Connector (Male) z Fuel Tank Cap
0 Propeller a Remote Control x Air Vent Screw
q Starter Handle s Main Switch c Fuel Pick Up Elbow
 16

INSTALLATION
1. Mounting the outboard motor on boat
! �������
Most boats are rated and certified
in terms of their maximum allowable
horsepower, as shown on the boat’s
certification plate. Do not equip your boat
with an outboard motor that exceeds this
limit. If in doubt, contact your dealer.
3 Do not operate the outboard motor until it
has been securely mounted on the boat in
accordance with the instructions below.
Installation
■ Single-engine Installation
Set engine at center of boat.
Center of Boat
Boat Transom
Transom matching
1 Be sure that the anti ventilation plate
of the outboard motor is 30-50mm
(1.2-2 in) below the bottom of hull.
If the above condition cannot be
met due to the shape of the bottom
of your boat, please consult your
authorized dealer.
Bottom of hull
30-50 mm
(1.2-2 in)
Anti Ventilation Plate
2 To attach the outboard motor to the
boat, tighten the clamp screws by
turning their handles.
Also, use the bolts to secure
the outboard motor brackets on
transom board.
Secure the outboard motor with a
rope to prevent loss overboard.

Note
■ Twin-engine Installation A rope is not included in the standard
When installing two outboard accessories.
engines, be sure to keep an interval
of approximately 580 mm (22.8 in)
between the two. Washer
Approx.580 mm (22.8 in)

Clamp
screw
*option

Nut &
Bolt Washer

! �������
• Before beginning the running test,
check that the boat with maximum
capacity loading floats on the
water in a proper attitude. Check
the position of water surface on
the driveshaft housing. If the water
surface is near the bottom cowling,
in high waves, water may enter the
engine cylinders.
• Incorrect outboard motor mounting
height or existence of underwater
object(s), such as hull bottom
design, bottom surface conditions
or underwater accessories,
can cause water spray possibly
reaching the engine through an
opening of the bottom cowling
during cruising. Exposing the
engine to such conditions for
extended periods can lead to
severe engine damage.
! �������
Mounting bolts should be installed with
the bolt head at inside surface of the
transom. Mounting bolts installed with
the threaded end at the inside surface
of the transom can cause personal
injury.
Notes
1. Apply sealing agent, such as
silicone sealed between the bolts
and the transom board holes before
tightening the bolts.
2. Be sure to tighten the mounting bolt
nuts to the specified torque.
(30 Nm (3.0kgf)13ft · lb)
INSTALLATION 17
! �������
• Mounting the outboard motor without
following this manual can lead to
unsafe conditions such as poor
maneuverability, lack of control or
fire.
• Loose clamp screws and/or mounting
bolts can lead to the release or
displacement of the outboard motor,
possibly resulting in lost of control and/
or serious personal injury. Be sure that 3
fasteners are tightened to the specified
torque (30 Nm (3.0kgf)13ft·lb). Check
the fasteners for tightness from time to
time.
• Be sure to use outboard mounting
fasteners included in the outboard
motor package or their equivalents
in terms of size, material, quality and
strength.
Tighten fasteners to the specified
torque (30 Nm (3.0kgf)13ft·lb). Test
cruise to check if fasteners are
tightened securely.
• Outboard motor mounting must
be performed by trained service
person(s) using lift or hoist with
sufficient capacity.
 18 INSTALLATION

1 Fitting of holder cap and sleeve B

2. Installing the remote control devices
guide

It is recommended that you consult Throttle side......Fit the holder cap

with your authorized dealer for to the end of the cable and fix it
installation adjustment of the remote by the nut.
control device.
Holder
cap Spring
Ball Washer Cable outer
■ Installation of the Remote Control holder Nut groove
Cables (Box side) :
3 Fo l l o w t h e i n s t r u c t i o n m a n u a l
Throttle cable
provided with the remote control.

Shift side......Fit the sleeve B guide

■ Installation of the Remote Control
on your boat : to the end of the cable and fix it
Fo l l o w t h e i n s t r u c t i o n m a n u a l by the nut.
provided with the remote control.
Sleeve B guide
Lock pin Cable outer
groove
■ Installation of the Remote Control Nut
Cable (engine side) and the Cord Spring

Assembly (Wiring Harness) :

Spring pin Shift cable

! ������� ! �������
When using other than Tohatsu’s genuine Be careful not to loop the remote
remote control box, DO NOT select the control cables to a diameter of 406
one without neutral safety switch that mm (16 inches) or less.
prevents in-gear start.
Use of remote control box without
neutral safety switch can allow start of
engine with gear at other than neutral
shift, potentially leading passengers to
falling or causing passenger to be thrown
overboard.
 INSTALLATION 19

2 Fitting of Remote Control Cable to Engine

Throttle side......Set the throttle cable to the cable clip and then connect the holder
cap to the ball joint of advancer arm.
Shift side......Set the shift cable to the cable clip and then insert the lock pin at the
shift lever fitting hole and turn it 90° to lock it.

Spring B guide
Spring
Spring pin
C.D. unit Advancer arm

3
Lock pin

Shift lever
Cable outer-
groove Ball joint
Cable of the
shift side

Washer
Ball holder

Holder cap
Clamp
Spring
Shift cable clip
Washer

Steering hook plate

Cable of the
throttle side

Cable clip Grommet is installed on

the Lower motor cover
Lower cowl Cable outer groove

Note Note
Put the control lever in the Neutral Confirm whether the engine side shift
position and the free accel lever in the is in gear when shifting the control
fully closed position. lever of the remote control to its first
position in Forward or Reverse (about
32°) and whether the throttle of the
carburetor is fully open when shifting
the lever further.
Confirm whether the carburetor’s
throttle is fully closed when the control
lever is shifted to the Neutral position.
If it is not, adjust the position of the ball
holder.
 20 INSTALLATION

3 Connecting the Cord Assembly (Wiring Harness)

Pass the cord assembly from the remote control through the hole in the lower cowl
and connect the electric terminals and then clamp the cord assembly according to
the drawing below.

Choke solenoid

Blue

3
Blue
Rectifier
C.D unit

from the
Remote control
Starter solenoid
Clamp Fuse wire

R
Gr
Gr
R
Clamp Battery cord
Br
Cord assembly
B R
R
Clamp
Br

! �������
Do not disconnect the cord assembly
when the outboard motor is in
operation or you will lose control of the
outboard motor.

3. Installing the battery
1 Place the battery box in a convenient
position away from possible water
spray. Securely fasten both the box
and the battery so they do not shake
loose.
Note
Minimum recommended battery :
12V, 40AH (465 Marine Cranking
Amps (MCA) or 350 Cold Cranking
Amps (CCA)) Specifications and
features of batteries vary among
the manufacturers. Consult the
manufacturer for details.
! �������
Battery electrolyte contains sulfuric
acid and thus is hazardous, causing
a burn if it comes in contact with your
skin, or poisonous if swallowed.
KEEP BATTERY AND ELECTROLYTE
AWAY FROM REACH OF CHILDREN
When handling the battery, be sure to:
• Read all warnings shown on the
battery case
• Prevent electrolyte from coming in
contact with any part of your body.
Contact can cause serious burn or,
if it comes in contact with your eye,
loss of sight. Use safety glasses
and rubber gloves.
In case battery electrolyte comes in
contact with:
• Skin, flush thoroughly with water.
• Eye, flush thoroughly with water,
and then seek immediate medical
treatment.
In case battery electrolyte is
swallowed:
• Seek immediate medical treatment.
INSTALLATION 21
! �������
Battery generates explosive hydrogen
gas. Be sure to:
• Charge the battery in a well-
ventilated place.
• Place the battery away from any
source of fire, sparks and open
flames such as burners or welding
equipment.
• Do not smoke when handling the
battery. 3
• Do not smoke near the battery when
the battery is charging.
! �������
• Make sure that the battery cords do
not get stuck between the outboard
motor and boat when turning, etc.
• The starter motor may fail to
operate if the cords are incorrectly
connected.
• Be sure to correctly connect the (+)
and (−) cords. If not, the charging
system will be damaged.
• Do not disconnect the battery
cords from battery while the engine
is operating, the electrical parts
could be damaged.
• Always use a fully charged battery.
! �������
Do not use a battery that is not
recommended. Use of a battery
not recommended can lead to poor
performance of, and/or damage to, the
electrical system.
 22 INSTALLATION

2 Connect the positive lead (+) to the

positive terminal (+) of the battery,
and then connect the negative lead
(−). When disconnecting the battery
always remove the negative lead (−)
first. After connecting the positive
terminal (+), securely place a cap on
it to prevent short circuits.

Battery cable
(black)
Battery cable
(red)
 23

PRE-OPERATING PREPARATIONS
! ������
Consult an authorized dealer for details
on handling of gasoline, if necessary.
Gasoline and its vapors are very
flammable and can be explosive.
When carrying a fuel tank containing
gasoline:
1. Recommended gasoline types
! �������
Use of low-quality gasoline results in
a short engine life as well as starting
difficulties and other engine problems.
We recommend use for Fuel stabilizer.

• Close the air vent screw of fuel tank

cap, or gasoline vapor will be emitted Use of unleaded gasoline
through the air vent screw, creating a
fire hazard.
Use a major brand of automotive
unleaded gasoline with a minimum
4
• Do not smoke.
pos ted oc tane r a ting o f 91RON.
When or before refueling : Automotive gasoline that contain fuel
• Stop the engine, and do not start the injector cleaner are preferred for added
engine during refueling. internal engine cleanliness. Leaded
• Do not smoke. gasoline is acceptable in areas where
• Be careful not to overfill fuel tank. Wipe unleaded gasoline is not available.ere
up any spilled gasoline immediately. unleaded gasoline is not available.
When or before cleaning the gasoline tank :
• Dismount fuel tank from the boat.
• Place the fuel tank away from every
source of ignition, such as sparks or
open flames.
• Do the work outdoors or in well
ventilated area.
• Wipe up any spilled gasoline immediately.

After cleaning gasoline tank :

• Wipe up any spilled gasoline immediately.
• If the fuel tank is disassembled for
cleaning, reassemble carefully. Imperfect
assembly may cause a fuel leak, possibly
leading to fire or explosion.
• Dispose of aged or contaminated
gasoline in accordance with local
regulations.
 24 PRE-OPERATING PREPARATIONS

Use of alcohol free gasoline And, in case any of such abnormality

! �������
Use of gasoline containing alcohol can
cause engine starting and/or operating
difficulties, wear of and damages to
engine parts, and deterioration of
chemical parts, which may lead to
shortening of your outboard motor’s life.
Note
The adverse effect caused by the alcohol
4 content is more severe with methanol than
with ethanol.
TOHATSU recommend the use of
gasoline if its ethanol content is less
than 10% or methanol content is less
than 5%, only in case alcohol free
gasoline is not available.
is found, discontinue the use of such
ga s oline a nd c on t a c t our de a le r
immediately.
Damages resulting from the use of
gasolines that contain alcohol are not
covered under the limited warranty.
Fuel tank capacity : 25 liters (6.6 U.S. gal)
Fuel Tank : When using a fixed fuel
tank in place of genuine fuel tank, it is
recommended to select a one with a
structure facilitating interior cleaning.
! �������
Do not fill the fuel tank over capacity. The
rise of gasoline temperature may cause
gasoline to expand which, if overfilled, may
leak through air vent screw when it is open.
Leaking gasoline is a dangerous fire hazard.

The alcohol component of the gasoline

absorbs moisture from the air, which
may disturb regular fuel flow in the fuel
system, and also accelerate rusting of
engine parts.
Mixing of the moisture in the engine oil
can also deteriorate the properties of
the lubricant.
If the use of gasoline containing alcohol
is inevitable, or presence of alcohol is
suspected in the gasoline, it is strongly
recommended to add a filter that has
water separating capability, and check
the fuel system for leaks and mechanical
parts for corrosion and abnormal wear
more frequently.
 PRE-OPERATING PREPARATIONS 25

2. Recommended engine oil Note

Use of engine oils that do not meet
Use a genuine engine oil or
these requirements will result in reduced
recommended one. Refer to your engine life, and other engine problems.
Distributor.
Will not recommend use of other two
Add engine oil into fuel oil tank. The
stroke engine oil.
mixing ratio with gasoline is 1 : 50 (one
part oil and 50 parts gasoline). Mix well
! ������� by hand. The mixing ratio during break-
Do not mix different brands of oil. in running is 1 : 25.
Mixing different brands of oil, or different
types of oil even if the brand is the same, Mixing Ratio
may cause gelling, resulting in possible
filter screen blockage. This could result
Engine Oil : Gasoline 4
in serious engine damage because of During break-in 1 : 25
impaired lubrication performance.
After break-in 1 : 50

Oil Fuel by Oil Mixing (1:25, 1: 50)

1.2L
1.1L
1.0L
(1:25)
0.9L
0.8L 1: 25
0.7L
0.6L
0.5L
0.4L (0.5: 25)
(0.4:10)
0.3L 1: 50
0.2L
0.1L (0.2:10)

0 2L 10L 25L 30L

Gasoline
 26 PRE-OPERATING PREPARATIONS

Engine oil – gasoline mixing

procedure
For quantities of engine oil and
gasoline to be pre-mixed, refer to
table in previous page.

! �������
● Do not use other than two stroke
engine oil with specified grade, or
the engine may be damaged.
● Do not use fuel prepared in other
than specified mixing ratio.
- Lack of engine oil can cause
4 severe engine trouble such as
piston seizure.
- Excess of engine oil can shorten
spark plug life, and/or cause
increase of noxious exhaust.

■ When portable fuel tank is

used for operation of outboard
motor(s):
1 Pour engine oil into fuel tank,
and then, gasoline.
2 Put cap on the tank, and close
tightly.
3 Close air vent plug tightly.
! �������
2 Pour engine oil into fuel
container, and then, gasoline.
3 Put cap on the container, and
close tightly.
4 Shake the container to mix
engine oil and gasoline well and
even.
5 Pour the mixture into fuel tank.

Loose cap or air vent plug can cause leak

of fuel during shaking the tank. Notes
● It is recommended to pre-mix by
4 Shake the tank to mix engine oil using separate fuel container.
and gasoline well and even. Attempting to pre-mix in the fuel
tank built-in the boat can make the
mixture uneven.
■ When fuel tank built in the boat
● If built-in fuel tank is used for
is used for operation of outboard mixing, pour engine oil into the
motor(s): tank little by little while putting
1 Prepare separate fuel container gasoline into the tank.
for pre-mixing.
 PRE-OPERATING PREPARATIONS 27

3. Break-in

Your new outboard motor and lower

unit require break-in for the moving ! �������
components according to the Operating the outboard motor without
conditions described in the following break-in can shorten service life of the
time table. product.
If any abnormality is experienced
during the break-in:
• Discontinue the operation
immediately.
• Have the dealer check the product
and take proper action(s) if
necessary.
4
1-10min 10min-2hrs 2-3hrs 3-10hrs After 10hrs

Less than 1/2 Less than 3/4 Full throttle

Throttle Position Idle 3/4 throttle
throttle throttle available

Approx.
Full throttle run 4,000 rpm.
Approx.
Speed allowed for 1 min Full throttle run
3,000 rpm max
every 10 min allowed for 2 min
every 10 min

Note
Proper break-in allows outboard motor
to deliver it full performance for longer
service life.
Fuel mix ratio for break-in
Gasoline 25: Genuine Engine Oil 1
● 25:1 when using genuine engine oil
or the recommended one (TCW3).
! ������
Do not operate the outboard motor
in closed area or area with no forced
ventilation.
Exhaust gas emitted by this outboard
motor contains carbon monoxide
that will cause death if inhaled
continuously. Inhaling the gas initially
causes symptoms such as feeling of
sickness, drowsiness and headache.
During operation of the outboard motor :
• Keep peripheral area well
ventilated.
• Always attempt to stay on the
windward side of emission.
 28

ENGINE OPERATION
1. Starting
! �������
In case engine starts in gear, do not
start cruising. Stop engine immediately
and consult an authorized dealer.
2 Attach the fuel connector to the
engine connector.
The arrow mark on the primer bulb
should be facing the engine.
Stop
switch

Note
Stop
The engine will not start unless switch lock
the switch lock has been properly Hook
connected into the emergency stop Fuel connector
switch.

5 ! ������� 3 Feed fuel to the carburetor by

Do not operate the engine with gear squeezing the primer bulb until it is
case out of water.
firm.
Severe personal injury, or engine
damage will result.
Arrow mark to Engine

to Fuel tank side

1 Loosen the air vent screw on the
tank cap.
Primer bulb
Air Vent Screw
 ENGINE OPERATION 29

■ 9.9D2, 15D2 and 18E2 type 5 Turn the throttle grip until the mark
4 Place the shift lever in the Neutral on the grip faces the triagular mark
position. on the steering handle.

Be sure that the shift is in Neutral when
starting the engine.
This model is provided with start in gear
protection.
6 Pull out the choke knob all the way.
(No choke operation is necessary
when the engine is warm.)
Throttle grip

Neutral (N)
Choke knob
Shift lever

! �������
If the engine starts in gear, do not use ■ 9.9D2, 15D2 and 18E2 type
it. Contact an authorized dealer. 7 Pull the starter handle slowly until
you feel resistance. Then pull it
quickly.
Note Slowly Quickly

Start-in-gear protection prevents

engine from starting at other than
neutral shift. In-gear starting of engine
will move the boat immediately,
potentially leading to falling down or
causing passenger(s) to be thrown
overboard.
 30 ENGINE OPERATION

■ EF type ■ EP type
7 Push the starter button. 4 Insert the main switch key.
5 Set the control lever in the Neutral
8 Release pushing the button when position.
the engine has started. Neutral (N)

Starter button
Fully open
Control
lever

Fully closed
Free accel lever

Main switch
key
Stop
switch

5 Note
6 Raise the free accel lever a little (both
of cold engine and warm engine).
7 Turn the main switch key to START
If use the choke knob for the engine
start, push back it when the engine position. Then, continuously push
has started. the key to operate the choke.

Note
Choke operation is not necessary if the
engine is warm.

8 Stop pushing the key when the

engine has started.
The key returns to the original
position, automatically.

9 Returns the Free accel lever to close
position.
Lock button
ON
OFF
Push to
operate
choke
Note
The free accel lever can raise when
the control lever shift is in Forward or
Reverse.
! �������
Do not keep turning starter motor for
over 3 seconds, or the battery may
be consumed, potentially making the
engine starting impossible and/or
damaging the starter.
If cranking over 3 seconds fails to
start engine, return main switch to
"ON", and crank engine again after 5
seconds or more.
Do not engage the starter motor after
the engine has started.
ENGINE OPERATION 31
If the recoil starter fails to operate
• Remove the top cowl and the recoil
starter. Wrap a rope around the
starter pulley then pull quickly to
start.
• Use a 10 mm socket wrench as a
rope handle.
5
! �������
Be careful that your clothes or other
items do not get caught in the rotating
engine parts.
To prevent accident and injury, do not
re-attach the recoil starter after the
engine has been started using the
emergency starter rope. Be sure to put
the top cowl back on.
Immediately contact an authorized
dealer when reaching shore.
! �������
• Be sure that no bystander(s) is
within 2 meters from back of
starting operator.
• Do not operate the outboard motor
with top cowl removed from the
power unit, or contacting turning
flywheel which can lead to serious
personal injury.
 32 ENGINE OPERATION

2. Warming up the engine ■ Engine speed

Warm the engine at low engine speeds
for about three minutes. This allows the
lubricating oil to circulate to all parts
of the engine. Operating the engine
without warm up shortens the engine's
life.
Be sure to check that cooling water is
coming out of the cooling water check
port during warm up.
Idling speed after warming up.
Clutch in (In gear) Clutch off (Out of gear)
800 rpm 950 rpm
■ Propeller selection
Propeller must be selected that
will allow the engine to reach
recommended rpm when cruising at
wide-open throttle.
Model Wide-open throttle rpm range

! ������� 9.9D2 4,500 - 5,300 rpm

15D2/18E2 5,200 - 5,800 rpm
If the engine is operated without water

5 discharging from the check port or idle

port, the engine may over heat.
Genuine propellers are listed on
PROPELLER TABLE of this manual.

Idle port

Cooling water check port

! �������
Be sure to stop engine immediately
if cooling water check port is not
discharging water, and check if cooling
water intake is blocked. Operating
engine could lead to overheating
potentially leading to engine damage.
Consult an authorized dealer if the
cause cannot be found.
 ENGINE OPERATION 33

3. Forward and reverse ■ 9.9D2, 15D2, 18E2 and EF type

! �������
Before shifting into forward or reverse,
make sure that boat is properly moored Reverse Forward Shift lever
and outboard motor can be steered fully
to the right and left. Make sure that no
swimmer(s) is ahead or astern of the boat.

! �������
• Attach other end of emergency
stop switch tether to the operator's
clothing or arm and keep it
attached during cruising.
! �������
• Do not attach the tether to a part
of clothing that can be torn easily
Severe damage, and personal injury,
may occur if shifting at high engine 5
when pulled. speed.
• Arrange the tether so that will not be Engine must be in the slow idle
caught by any object when pulled. position before shifting is attempted.
• Be careful not to pull the tether
accidentally during cruising.
Unintentional stop of engine can Forward
cause loss of control of outboard
Turn the throttle grip to reduce engine
motor. Rapid loss of engine power
can lead to falling down or causing speed. When the engine reaches
passenger(s) to be thrown overboard. trolling (or idling) speed, quickly pull the
shift lever to the Forward position.

! �������
Be sure to connect the emergency tethered
stop hook to your waist or clothing.
The engine will shut down when the
switch lock becomes disconnected
from the engine.
Reverse
Reduce engine speed, when the engine
reaches trolling (or idling) speed, quickly
push the shift lever to the Reverse
position.

! �������
Notes
Before shifting, make sure that no
• Do not increase engine speed swimmer(s) or obstacle(s) is ahead or
unnecessarily in reverse. astern of the boat.
• Confirm that the reverse lock lever
is at “LOCK” position before running
your motor.
 34 ENGINE OPERATION

EP type
! ������� Control lever

Be sure to warm up engine well before

starting cruise. Operating cold engine
may cause damage to your motor. Lock button

Neutral
Note d (N) Re
ar Shif
t Shif
t ( verse
rw
Idle speed may be higher during Fo (F) abou
R)
ut
warming up of engine. If shifted to abo ° 3 2
t
32 °

Th
ro
Forward or Reverse during warming

ttl
tle

e
Ful

e
lly

los
up, it may be difficult to shift back to Fu en

rot

ly c

ly c
op

Th

los
neutral. In such case, stop engine, shift

Ful
e
Free
to neutral, and restart engine to warm Fully accel
up. open lever

5 Note
Frequent shifting to forward or reverse
can accelerate wear or degradation of
parts. In such case, replace gear oil
earlier than the period specified.
Forward
Quickly push the control lever to the
Forward (F) position 32˚, where the
gear is connected, while lifting up on
the lock button located at the bottom
of the control lever grip. Further shifting
will open the throttle.

Reverse
Quickly pull the control lever to the
Reverse (R) position at 32˚, where the
gear is connected, while lifting up on
the lock button located at the bottom
of the control lever grip. Further shifting
will open the throttle.

Notes
• The control lever is inoperative unless
the free accel lever is in the fully closed
position.
• Reduce the engine speed when the
control lever is in Neutral and do not
increase the engine speed unnecessarily.

4. Stopping
9.9D2, 15D2, 18E2 and EF type
Stop switch
Stop switch
lock
Hook
1 Turn the throttle grip to the slow
position.
2 Put the shift lever in the Neutral
position.
Run the engine for 2-3 minutes at
idling speed if it has been running at
full speed.
3 Push the stop switch to stop the
engine or release the stop switch
lock.
! �������
• Do not shift into Reverse during
planing, or control will be lost
leading to serious personal injury,
boat may swamp, and/or hull may
be damaged.
• Do not shift into Reverse during
cruising, or control may be
lost, falling down or causing
passenger(s) to be thrown
overboard. Leading to serious
personal injury, and steering
system and/or shifting mechanism
may be damaged.
ENGINE OPERATION 35
EP type
ON
OFF
Stop switch
lock
(N)
5
1 Put the shift lever in the Neutral
position and run the engine for 2-3
minutes at idling speed if it has been
running at full speed.
2 Turn the main switch key to the OFF
position.
Notes
• After stopping the engine, close the
air vent screw on the tank cap.
• Disconnect the fuel connector of
the engine or the fuel tank.
• Disconnect the battery cable of the
EF or EP type engine, if the engine
will not be used for more than 3
days.
 36 ENGINE OPERATION

5. Trim angle

The trim angle of the outboard motor

can be adjusted to suit the transom
angle of the hull, and load conditions.
Choose an appropriate trim angle that
will allow the anti ventilation plate to
run parallel to the water surface during
operation. Thrust rod

■ Proper trim angle Hi

gh r
The position of the thrust rod is correct er we
Lo
if the hull is horizontal during operation.
Perpendicular to the
water surface
! �������
5 • Do not put hand or finger in
between outboard motor body and
clamp bracket when adjusting trim
angle to prevent injury in case the
outboard motor body falls.
• Unsuitable trim position can cause
■ Improper trim angle loss of control of boat.
Set the thrust rod lower if the bow of When testing a trim position, run
the boat rises above horizontal. boat slow initially to see if it can be
controlled safely.

! �������
Excessive trim up or down may lead
to unstable boat operation, potentially
causing the steering difficulty that
leads to accident during cruising.
■ Improper trim angle • Do not cruise at high speed if
Set the thrust rod higher if the bow of improper trim position is suspected.
the boat is below horizontal. Stop the boat and readjust trim
angle before continuing cruise.

6. Tilt up, tilt down and shallow water operation
! �������
When tilting up or down, be careful not
to place your hand between the swivel
bracket and the stern bracket.
Be sure to tilt the outboard motor
down slowly.
Note
Stop the engine before tilting up.
■ Tilt up
Push the reverse lock lever down until it
stops. (This is the tilt up position.) Now,
tilt the outboard motor all the way up
until it is locked in place.
Reverse lock lever
ENGINE OPERATION 37
! �������
• Do not put hand or finger in
between outboard motor body and
clamp bracket when adjusting trim
angle to prevent injury in case the
outboard motor body falls.
• When tilting up outboard motor with
fuel joint for over a few minutes,
be sure to disconnect fuel hose or
close fuel cock, or fuel may leak,
potentially catching fire.
! �������
Do not tilt up outboard motor during
operation, or engine may be damaged
from overheating due to lack of 5
sufficient cooling water.
■ Tilt down
Pull the reverse lock lever upward until
it stops. (This is the tilt down position.)
Now, lift up the outboard motor slightly,
and then allow gravity to lower it for
you.
Reverse lock lever
Tilt Down posotion
Tilt Up posotion
 38 ENGINE OPERATION

■ Shallow water operation 1 Shallow water running position:

Put the reverse lock lever in the tilt
! ������� up position, and tilt up the outboard
motor to put the outboard motor in
During shallow water operation, be
the shallow water running position.
careful not to place your hand between
the swivel bracket and the stern Reverse lock lever
bracket.
Be sure to tilt the outboard motor down
slowly.

Note
Slow down to trolling speed, and shift
into Neutral before setting outboard
motor to shallow water drive position.

5 2 Return to normal running position:

! ������� Put the reverse lock lever in the tilt
down position, slightly lift up the
• Run at lowest possible speed when outboard motor, and then put it
using shallow water drive.
down.
• Tilt lock is disabled when in shallow
water drive position. Reverse lock lever
• When driving shallow water, be Tilt Down posotion
careful not to strike outboard motor
against sea bottom, or propeller
may be pushed out of water,
resulting in loss of control.

Tilt Up posotion

! �������
While in shallow water drive position,
do not operate the outboard motor in
reverse. Operate the outboard motor
at slow speed and keep the cooling
water intake submerged.
 ENGINE OPERATION 39

! �������
Do not tilt up outboard motor while
engine operates, or no cooling water
may be fed, leading to engine seizure
due to overheating.
Sub water inlet

! �������
Do not overtilt outboard motor
when driving shallow water, or air 5
may be sucked through subwater
inlet, potentially leading to engine
overheating.

! �������
Do not tilt up or down outboard motor
when swimmer(s) or passenger is near
to prevent them from being caught
between outboard motor body and
clamp bracket in case the outboard
motor body falls.

! �������
When tilting up outboard motor with
fuel joint for over a few minutes, be
sure to disconnect fuel hose or close
fuel cock, or fuel may leak, potentially
catching fire.
 40

REMOVING AND CARRYING THE OUTBOARD MOTOR

1. Removing the outboard motor 3. Storing the outboard motor

1 Stop the engine. Outboard motor should be stored in a

2 Disconnect the fuel connector, vertical position.
the remote control cables and the
battery cords from the outboard Note
motor.
3 Remove the outboard motor from If the outboard motor must be laid
down be sure the tiller handle faces
boat and completely drain the water
down as shown in the drawing above.
from the gear case. Elevate power unit 2 inches to 4 inches
if traveling to avoid oil spillage.
! ������� Power head
Engine may be hot immediately after
Propeller
operating and could cause burns
if touched. Allow Engine to cool
down before attempting to carry the
outboard.

6 Handle

2. Carrying the outboard motor ! �������

Keep the outboard motor in a vertical Do not carry or store outboard motor
position when carrying. in any of positions described below.
Otherwise, engine damage or property
damage could result from leaking oil.

! �������
Close air vent screw of fuel tank and
fuel cock before carrying or storing
outboard motor and fuel tank, or fuel
may leak, potentially catching fire.
 41

TRAILERING
! �������
Do not go under outboard motor tilted
up even if it is supported by support
bar, or accidental fall of outboard motor
could lead to severe personal injury.
! �������
Close air vent screw of fuel tank and
fuel cock before carrying or storing
outboard motor and fuel tank, or fuel
may leak, potentially catching fire.
! �������
When trailering the outboard motor
should be in a vertical (normal running)
position, fully down. Trailering in the
tilted position may cause damage to
the outboard motor, boat, etc.
If trailering with outboard motor fully
down is not available (the gear case
skeg is too close to the road in a
vertical position), fix the outboard
motor securely using a device (like a
transom saver bar) in the tilted position.

! �������
When taking outboad motor from
package or removing outboad motor from
the boat, never release the lock lever. If
the lock lever is released, it will very easy
for the clamp bracket to spring up to the
tilting direction because it is not fixed.

*Care must be taken so as not to 7

release lock lever by accident.
*For more safety, tie the clamp bracket
to the outboard motor with a rope.
*Pay attention to the tilting direction so
as not to be injured by the springing
stern bracket.
! �������
! �������
Please disconnect fuel connector
except when operating engine.
Fuel leakage is a fire or explosion
hazard, which can cause serious injury
or death.

The tilt support device supplied on your

outboard motor is not intended for towing.
It is intended to support the outboard motor
while the boat is docked, beached, etc.
 42

ADJUSTMENT
1. Steering friction 2. Remote control lever load

The steering friction can be adjusted (Throttle friction adjustment screw)

in accordance with your preference by
turning the steering adjusting bolt.
To adjust the load of the remote
control lever, turn the throttle friction
adjustment screw on the front of
the remote control. Turn clockwise
to increase the load and counter-
clockwise to decrease it.

Lighter Heavier

Lighter Heavier

Throttle friction
Note adjustment screw

The steering adjust bolt is used to adjust

the sliding load of the steering, but not
to fix the steering. If excess tightning
given to the bolt may lead a cause of

8
damage to the swivel bracket.

! �������
Do not overtighten the throttle grip
or remote control tensioner or it
could result in difficulty of movement
resulting in the loss of control causing
an accident and could lead to severe
injury.
 ADJUSTMENT 43

3. Trim tab adjustment ! �������

• Inappropriate adjustment of trim
If straight-line cruising can not be tab could cause steering difficulty.
achieved, adjust the trim tab located After installing or readjusting trim
under the anti ventilation plate. tab, check if steering load is even.
• If the boat veers toward the right, • Tighten trim tab bolt to specified
direct the trim tab towards A. torque.
• If the boat veers toward the left,
direct the trim tab towards B.
Trim tab
! �������
• Be sure that outboard motor is
secured to transom or service
B
stand, or accidental drop or fall
of outboard motor could lead to
A severe personal injury.
• Be sure to lock outboard motor
if it is tilted up, or accidental fall
of outboard motor could lead to
severe personal injury.
• Do not go under outboard motor
tilted up and locked, or accidental
Notes fall of outboard motor could lead to
severe personal injury.
• The trim tab also acts as an anode
to prevent electrolytic corrosion.
Therefore do not paint or grease
this part.
• After adjustment securely tighten
8
the trim tab fixing bolt.
• Check for looseness of the bolt and
the trim tab at regular intervals.
• Due to corrosion, the trim tab will
wear down over time.
The trim tab should be replaced
when it has eroded 2/3 of it's
regular size.
 44

INSPECTION AND MAINTENANCE

Care of your outboard motor
To keep your outboard motor in the
best operating condition, it is very
important that you perform daily and
periodic maintenance as suggested in
the maintenance schedules that follow.

! �������
• Your personal safety and that of
your passengers depends on how
well you maintain your outboard
motor. Carefully observe all of
the inspection and maintenance
procedures described in this
section.
• The maintenance intervals shown in
the checklist apply to an outboard
motor in normal use. If you use
your outboard motor under severe
conditions such as frequent
full-throttle operation, frequent
operation in brackish water, or
for commercial use, maintenance
should be performed at shorter
intervals. If in doubt, consult your
dealer for advice.
• We strongly recommend that you
use only genuine replacement parts
on your outboard motor. Damage
9 to your outboard motor arising from
the use of other than genuine parts
is not covered under the warranty.
 INSPECTION AND MAINTENANCE 45

1. Daily inspection

Perform the following checks before

and after use. ! �������
Do not use outboard motor on which any
abnormality is found during pre-operation
check or it could go into trouble during
cruising potentially leading to accident.

Item Points to Check Action

• Check the amount of fuel in the tank. Replenish
Fuel System • Check for debris or water in the fuel filters. Clean or replace
• Check the rubber hoses for fuel leakage. Replace

• Check that the main switch functions normally. Replace

• Check that the battery electrolyte level and specific gravity Replenish or recharge
are normal.
Electrical • Check for loose connections on the battery terminal. Retighten
Equipment • Check that the stop switch functions normally and make Remedy or replace
sure the lock plate is there.
• Check cords for loose connections and damage. Correct or replace
• Check the spark plugs for dirt, wear and carbon build-up. Clean or replace
• Check that the choke solenoid and valve for the carburetor Replace
Choke and function normally.
Throttle System • Check if the carburetor and magneto work normally when Correct
turning the throttle grip, and check links for looseness.
• Check the rope for wear and chafing. Replace
Recoil Starter
• Check the ratchet engagement. Correct or replace

• Check that clutch engages correctly when operating the Adjust

Clutch and shift lever and remote control.
Propeller
System
• Visually check propeller for bent or damaged blades.
• Check the propeller nut is tightened and the split pin is
Replace
9
present.

Installation of • Check all the bolts attaching the motor to the boat. Tighten
Motor • Check the thrust rod installation. Tighten

• Check that cooling water is discharged from the cooling Repair

Cooling Water
water check port after the engine has started.

• Check that there are tools and spare parts for replacing
Tools and Spares spark plugs, the propeller, etc.
• Check that you have the spare rope.

• Check the operation of the steering handle and remote

Steering Devices Repair
control.
• Check if the anode and trim tab are securely installed. Repair or Replace
Other Parts • Check the anode and trim tab for corrosion and
deformation.
 46 INSPECTION AND MAINTENANCE
Washing outboard motor
If outboard motor is used in salt water,
brackish water or water with a high
acidic level, use fresh water to remove
salt, chemicals or mud from exterior
and cooling water passage after every
cruising or before storing outboard
motor for long time. Before flushing,
remove the propeller and the forward
thrust holder.
! �������
Keep cooling water passage free of
clogs, or lack of cooling water flow
could lead to engine overheating,
potentially resulting in engine trouble.
Note
It is recommended to check chemical
properties of water on which your
outboard motor is regularly used.
! �������
Do not start engine without removing
9 propeller, or accidentally turning
propeller could cause personal injury.
! �������
Never start or operate the engine
indoors or in any space which is not
well ventilated. Exhaust gas contains
carbon monoxide, a colorless and
odorless gas which can be fatal if
inhaled for any length of time.
■ Use flushing plug.
1 Remove propeller (refer to Propeller
Replacement). Remove the water
plug from the outboard motor, and
screw in the flushing plug.
2 Attach a water hose to the flushing
plug. Turn on the water and adjust
the flow. (Be sure to seal the water
inlet and sub water inlet, located in
the gear case, with tape)
3 Insert a hose connected to a water
tap into the flushing plug and let the
water running.
4 Put the shift lever in the neutral
position and start the engine.
5 Make sure of cooling water flowing
out of water pump indicator hole
and continue engine running for 3 to
5 minutes.
6 Stop the engine and water supply.
Remove the flushing plug and tape,
and then reinstall the water plug and
the propeller.
Flushing
plug
! �������
Keep engine at idle speed during
flushing.
 INSPECTION AND MAINTENANCE 47

Replacing the propeller

A worn-out or bent propeller will lower
the motor's performance, and cause
engine trouble.
Before removing the propeller, remove
the spark plug caps from the spark
plugs to protect against personal injury.
! �������
Do not hold propeller with hand(s)
when loosening or tightening propeller
nut. Put a piece of wood block
between propeller blade and anti
ventilation plate to hold propeller.

! �������
Do not begin propeller removal and
installation procedure with spark
plug caps attached, shift in forward
or reverse, main switch at other than
"OFF", engine stop cord attached to
the switch, and starter key attached, or
engine could accidentally start leading
to serious personal injury. Disconnect
battery cable if possible.
! �������
• Do not install propeller without
thrust holder, or propeller boss
could be damaged.
• Do not reuse split pin.
• After installing split pin, spread the
pin apart to prevent it from falling
out which could lead to the propeller
coming off during operation.

1 Remove the split pin, propeller nut

and washer.
2 Remove the propeller and thrust
holder.
3 Apply genuine grease to the
propeller shaft before installing a
new propeller.
4 Install the thrust holder, propeller,
washer and propeller nut onto the
shaft. 9
5 Install a new split pin into the nut
hole and bend it.

Propeller

Propeller shaft Washer

Split pin

Propeller
thrust Nut
holder
 48 INSPECTION AND MAINTENANCE

Replacing the spark plugs

! �������
• Do not reuse spark plug with damaged
insulation, or sparks can leak through
crack, potentially leading to electric
shock, explosion and/or fire.
• Do not touch spark plugs immediately
after stopping engine as they will be
hot and could cause severe burns if
touched. Allow motor to cool down first.
Note
• Spark plug torque :
18.0 Nm (13.3 ft-lb) (1.8 kgf-m)
If a torque-wrench is not available
when you are fitting a spark plug, a
good estimate of the correct torque is
1/4 to 1/2 a turn past finger-tight. Have
the spark plug adjusted to the correct
torque as soon as possible with a
torque-wrench.

If the spark plug(s) is fouled, has carbon

build up, or is worn, it should be replaced.
When reusing spark plugs, remove dirt
from the electrodes and adjust spark
gap to specification.
Note
Replacing the anode
A sacrificial anode protects the outboard
motor from galvanic corrosion. Anode
is located on the gear case and clamp
bracket. When the anode is eroded
more than 2/3, replace it.

When inspecting the plug, always clean the Notes

gasket surface and use a new gasket. Wipe
off any dirt from the threads and screw in
the spark plug to the correct torque.
1 Stop the engine.
2 Remove the top cowl.
3 Remove the spark plug caps.
4 Remove the spark plugs by turning
• Never grease or paint the anode.
• At each inspection re-tighten the
anode attaching bolt. As it is likely
to be subjected to electrolytic
corrosion.

9 it counter-clockwise, using a 21 mm
(13/16 in) socket wrench and handle.
5 Attach spark plug and tighten to
specified torque.
Anode
(Trim tab)
Use spark plugs (NGK B7HS-10 or
BR7HS-10) or recommended ones
(CHAMPION L82 C or RL 82 C with 1.0
mm gap).

Spark gap : 0.9 - 1.0mm

(0.035 - 0.039 in)
Electrode
 INSPECTION AND MAINTENANCE 49

2. Periodic inspection

It is important to inspect and maintain your outboard motor regularly. At each interval
on the chart below, be sure to perform the indicated servicing. Maintenance intervals
should be determined according to the number of hours or number of months,
whichever comes first.

Servicing Interval
Item 10 hours 50 hours Every 100 Action Remarks
or or hours or
1 month 3 months 6 months

Strip, clean and adjust.

*Carburetor ●
Adjust idling.
Fuel Fuel filter ● ● ● Check and clean or Replace.
System
Piping ● ● ● Check and Replace.
Fuel tank ● ● Clean.
Check gaps. Remove carbon
Spark plugs ● ●
Ignition deposits or Replace.
*Ignition timing ● ● Adjust timing.
Check for salt deposits and
*Starter motor ●
battery cable condition.
Starting
Check Installation, fluid
System Battery ● ● ●
quantity, gravity.
Starter rope ● ● ● Check for wear or damage.
Check for bend blades,
Propeller ● ● ●
damage, wear.
Lower Change or replenish-oil and
Gear oil ● ● ●
Unit check for water leaks.
Replace impeller
*Water pump ● ● Check for wear or damage.
9
every 12 months.
Bolt and Nuts ● ● ● Retighten.
Sliding and Rotating Parts
● ● Apply and pump in grease.
Grease Nipples
Outer Equipment ● ● ● Check for corrosion.
Check for corrosion and
Anode ● ● Replace.
deformation.

*Have this handled by your dealer.

Note
Your outboard motor should receive
careful, and complete, inspection at
300 hours. This is the best time for
major maintenance procedures to be
carried out.
 50 INSPECTION AND MAINTENANCE

Cleaning the fuel filters and the ■ Fuel filter (for fuel tank)
fuel tank Remove the fuel pickup elbow of the
Fuel filters are provided inside the fuel fuel tank by turning it counterclockwise
tank and engine. and clean the fuel filter.

! ������� Fuel
pick up
elbow
Gasoline and its vapors are very
flammable and can be explosive.
• Do not start this procedure while
engine is operating or hot even
after stopping it.
• Place fuel filter away from every Filter
source of ignition such as sparks or
open flames.
• Wipe off gasoline well immediately ■ Fuel tank
if spilled. Water or dirt in the fuel tank will cause
• Install fuel filter with all related engine performance problems.
parts in place, or fuel leak could Check and clean the tank at specified
occur, leading to catching fire or
times or after the outboard motor has
explosion.
• Check fuel system regularly for been stored for a long period of time
leakage. (over three months).
• Contact authorized dealer for
fuel system services. Services by
unqualified person could lead to
engine damage.

■ Fuel filter (for engine)

Remove the cap, then clean the fuel
9 filter in the engine.

Carburetor Fuel filter

 INSPECTION AND MAINTENANCE 51

Replacing gear oil

! �������
Upper oil plug hole
• Be sure that outboard motor is
secured to transom or service
stand, or accidental drop or fall
of outboard motor could lead to
severe personal injury.
• Be sure to lock outboard motor
if it is tilted up, or accidental fall
of outboard motor could lead to
severe personal injury. 3 Install the upper oil plug, and then
• Do not go under outboard motor
remove oil tube nozzle and install
tilted up and locked, or accidental
fall of outboard motor could lead to the lower oil plug.
severe personal injury.
Note
1 Remove the oil plugs (upper and
If water in the oil, giving it a milky colored
lower), and completely drain the appearance. Contact your dealer.
gear oil into a pan.

Note
Use genuine gear oil or the
Water strainer recommended one (API GL-5: SAE
#80 to #90).
Required volume
: approx. 370 mL (0.10 U.S. gal.)

9
2 Insert the oil tube nozzle into the
lower oil plug hole, and fill with gear
oil by squeezing the oil tube until oil
flows out of the upper plug hole.

! �������
Do not reuse oil plug gasket. Always
use new gasket and tighten oil plug
properly to prevent entry of water into
lower unit.
 52 INSPECTION AND MAINTENANCE
3. Off-season storage
Before you put your outboard motor
in storage, it is a good opportunity to
have it serviced and prepared by your
dealer.
! �������
Before servicing the motor for storage:
• Remove the battery cables.
• Remove the spark plug caps from
the spark plugs.
• Do not run the motor out of the water.
■ Engine
1 Wash the engine exterior and flush
the cooling water system thoroughly
with fresh water. Drain the water
completely.
Wipe off any surface water with an
oily rag.
2 Use a dry cloth to completely wipe
off water and salt from the electrical
components.
3 Drain all fuel from the fuel hoses,
fuel pump, and carburetor, and
9 clean these parts.
Keep in mind that if gasoline is
kept in the carburetor for a long
time, gum and varnish will develop,
causing the float valve to stick,
restricting the fuel flow.
4 Remove the spark plugs and feed
genuine engine oil or storage
fogging oil in through the spark plug
holes.
The oil will be fed into the crank
case from the air silencer attached
to the carburetors. Turn the engine
over several times while feeding the
oil into it and make sure it is evenly
distributed.
5 Change the gear oil in the gear
case.
6 Apply grease to the propeller shaft.
7 Apply grease to all sliding parts,
8
joints, nuts, and bolts.
St and the outboard motor up
vertically in a dry place.
! �������
Be sure to use cloth to remove fuel
remaining in the cowl and dispose of it
in accordance with local fire prevention
and environment protection regulations.
■ Battery
1 Disconnect the battery cables.
2 Wipe off any chemical deposits, dirt,
or grease.
3 Apply grease or vaseline to the
battery terminals.
4 Charge the battery completely
before storing it for the winter.
5 Recharge the battery once a month
to prevent it from discharging and
the electrolyte from deteriorating.
6 Store the battery in a dry place.
■ Electric Starter Motor
Coat the internal pinion gears and the
shaft of the electric starter motor with
grease.
Do not put grease on the teeth of the
starter pinion or flywheel or increased
wear or damage will occur.
 INSPECTION AND MAINTENANCE 53

4. Pre-season check Specific Terminal Charge

Gravity at 20 °C Voltage (V) Condition

1 Check that the shift and throttle 1.120 10.5

Fully
discharged
function properly.
(Be sure to turn the propeller shaft 1.160 11.1 1/4 charged
when checking the shift function or else 1.210 11.7 1/2 charged
the shift linkage may be damaged.)
1.250 12.0 3/4 charged

1.280 13.2 Fully charged

Notes
The following steps must be taken 3 Check that the battery is secure
when first using the engine after winter
storage.
and the battery cables are properly
1 Fill up the fuel tank completely with installed.
25 liters (6.6 U.S. gals.)
Mixing ratio : Gasolne 25 : 1 Engine
oil
Use unleaded gasoline and genuine
Outboard Motor Oil. If this oil is
not available, use NMMA TC-W3
certified outboard motor oil.
2 Warm up the engine for 3 minutes
in the "NEUTRAL" position.
3 Run the engine for 5 minutes at the
slowest speed.
4 Run the engine for 10 minutes at
half speed.
In Steps 2 and 3 above, the oil
used for storage inside the engine
will be flushed out to assure optimum
performance. 9

2 Check the electrolyte level, and

measure the voltage and specific
gravity of the battery.
 54 INSPECTION AND MAINTENANCE

5. Motor submerged in water 6. Cold weather precautions

After taking your outboard motor out of If you moor your boat in cold weather
the water, immediately take it to your at temperatures below 0˚C (32˚F),
dealer. there is the danger of water freezing
The following are the emergency in the cooling water pump, which may
measures to be taken for a submerged damage the pump, impeller, etc. To
outboard motor, if you can not take it avoid this problem, submerge the lower
your dealer right away. half of the outboard motor into the
1 Wash the outboard motor with fresh water, or tilt the motor up above water
water to remove salt or dirt. level and pull the recoil starter several
2 Remove the spark plugs, and times to drain the water completely.
completely drain the water from the
engine by pulling the recoil starter
several times.
3 Inject a sufficient amount of genuine
engine oil through the spark plug
hole and into the crank case from
the carburetor side. Pull the recoil
starter several times to circulate the
oil throughout the outboard motor.

! �������
Do not attempt to start submerged
outboard motor immediately after it is
recovered, or engine could be severely
9 damaged.
 INSPECTION AND MAINTENANCE 55

7. Checking after striking underwater object

Striking the sea bottom or an

underwater object may severely
damage the outboard motor.
Immediately bring the outboard motor
to the dealer and ask for the following
checks.

1 Looseness or damage of power

unit installation bolts, gear case and
extension case bolts, propeller shaft
housing bolts, propeller or propeller
shaft upper and lower mount rubber
bolts, and/or mount bracket bolts.

Ask an authorized dealer to tighten

any loose bolts and nuts, and to
replace damaged parts.

2 Damage to mount rubber, the tilt

stopper, thrust rod, gears and
clutch, and/or propeller.

Ask an authorized dealer to replace

damaged or defective parts.
9
 56

TROUBLESHOOTING
If you encounter a problem, consult the check list below to determine the cause and
to take the proper action.
An authorized dealer will always be happy to provide any assistance and information.

High engine speeds not possible

Engine starting but stoping soon

Engine speed abnormally high

Engine speed abnormally low

Overheating of engine
Engine failing to start

Possible cause
Poor acceleration
Poor idling

● ● Empty fuel tank

● ● ● ● ● ● ● Incorrect connection of fuel sysytem

● ● ● ● ● ● ● Air entering fuel line

● ● ● ● ● ● ● Deformed or damaged fuel pipe

● ● ● ● ● ● ● Closed air vent on fuel tank

FUEL SYSTEMS

● ● ● ● ● ● ● Clogged fuel filter, fuel pump, or carburetor

● ● ● ● ● Use of improper engine oil

● ● ● ● ● Use of improper gasoline

● ● ● ● ● ● Excessive oil in mixture

● Shortage of oil in mixture

● ● Excessive supply of fuel

10 ● ● ● ● ● ● ● Poor carburetor adjustment

● ● ● ● ● ● Recirculation pipe broken

● ● ● ● ● ● ● Spark plugs other than specified

ELECTRIC SYSTEMS

● ● ● ● ● ● Dirt, soot, etc. on spark plugs

● ● ● ● ● ● No spark or weak spark

● Short circuit of engine stop switch

● ● ● ● ● Incorrect adjustment of ignition timing

 TROUBLESHOOTING 57

High engine speeds not possible

Engine starting but stoping soon

Engine speed abnormally high

Engine speed abnormally low

Overheating of engine
Engine failing to start

Possible cause
Poor acceleration
Poor idling

● Loose battery terminal connection, corrosion

EP and EF
ELECTRIC SYSTEMS

● Discharged battery
types
● Main switch trouble

● Lock plate not fitted to stop switch

● Disconnection of wire or loose ground connection

Insufficient battery capacity, loose terminal EP and EF

●
connection, corrosion types

● ● ● ● ● Incorrect adjustment of throttle link

● ● Insufficient cooling water flow, clogged or defective pump

● ● ● Faulty thermostat

● ● ● ● Cavitation or ventilation
OTHERS

● ● ● ● ● Incorrect propeller selecition 10

● ● ● ● ● ● Damaged and bent propeller

● ● ● ● Improper thrust rod position

● ● ● ● ● Unbalanced load on boat

● ● ● ● ● Transom too high or too low

 58 TOOL KIT AND SPARE PARTS

TOOL KIT AND SPARE PARTS

The following a list of the tools and spare parts provided with the motor.

Items Quantity Remark

Tool Bag 1
Pliers 1
Socket Wrench 1 10 X 13mm
Service Tools
Socket Wrench 1 21mm
Socket Wrench Handle 1
Straight Edge Screwdriver 1

Rope 1
Spare Parts Spark Plug 1 NGK B7HS-10
Split Pin 1
Fuel Tank 1
Parts Primer bulb 1 set
Packaged with Engine* Remote Control 1 set EP only
Remote Control Attachment 1 set EP only
* Not provided with the motor in some markets.

11
 OPTIONAL ACCESSORIES 59

OPTIONAL ACCESSORIES

Tachometer

Tachometer unit kit

Genuine grease (250g)

Genuine gear oil (500mL)

Touch-up Paint

Genuine Engine Oil (0.4L, 1L, 4L, 20L)

12
Flushing attachment

Extension cord for light

(Lights are available on the market.)
 60

PROPELLER TABLE
Use a genuine propeller.
A propeller must be selected so that the engine rpm measured at wide open throttle
while cruising is within the recommended range: 9.9D2 = 4,500 to 5,300 rpm; 15D2/
18E2 = 5,200 to 5,800 rpm.

Propeller Size Standard propeller on the model

Propeller Mark
(diameter × pitch) 18 15 9.9
9.25 × 11.5
Light boats 11.5
235 × 292
9.25 × 10
10
235 × 254
9.25 × 9
9 S&L S S
235 × 229
9.25 × 8
8 UL L & UL L & UL
235 × 203
Heavy boats 9.2 × 6.1
6
234 × 155

S : Short shaft
L : Long shaft
UL : Extra long shaft

13
MEMO
MEMO
 OWNER’S
MANUAL

OWNER’S MANUAL M 9.9

M 9.9 15
15 TOHATSU CORPORATION
18
18
Address : 5-4, 3-chome, Azusawa, Itabashi-ku,
TOKYO, 174-0051 JAPAN
Phone : TOKYO (03)3966-3117
FAX : TOKYO (03)3966-2951 OB No.003-11049-A
Website : www.tohatsu.co.jp
003-11049-A 1101NB
Printed in Japan

M9.9-15-18_E_cover_110107.indd 1 11.1.12 4:20:04 PM